Smart Orbiter v3.0 Mount for TwoTrees Sapphire Pro

Overview

This design lets you attach the Smart Orbiter v3.0 to the TwoTrees Sapphire Pro. 

My goal was to have a compact design that looks tidy and gives you a good view on the printhead. Also I designed with minimal support in mind.  

Features

• Smart Orbiter v3.0 on your TwoTrees Sapphire Pro (from 2020)
• in comparison to the stock hotend you gain a little bit of z-height
• you loose ~7 mm in the Y-Axis if you decide to use the 5015 Blower on the back side like me in the pictures
• bulit in belt tensioning
• some cable management points for zip ties

Bill of Material 

attaching the Smart Orbiter v3.0

• 6x M3x6 cylinder head screw (4 of them are already included in the initial Sapphire Pro)
• 2x M3x6 countersunk screw 

Belt tensioning

• 2x M3x20 
• 2x M3 Washers 
• 2x M3 heated insert 4 pieces of 1.75mm filament (ca 5mm) for Belt-holding

For the 5015-fan attachment

• 2x M4x18 countersunk screw
• 2x M4 nut
• 1x M2x10 Screw

Versions

1. “Vanilla” Version like i printed it
   
   Please note that you loose about 7mm on the y-axis due to the 5015-Blower fan.
   Also see pictures nr 8 and 9, i bent the Y-axis switch to trigger earlier, this was the simplest soluton for that.
   
   i combined it with my strain relief for the top exiting bowden tube (the M3x6 screws of the inital installation still fit)
   
   when Installing the second screw of the fan, the nut faces the extruder motor to loose less space
    
2. Version with integrated Strain-relief
   Version like Version 1 with additional strain-relief on the top where the bowden tube exits.
    
3. Version without integrated 5015 Fan-mount
   You can use the Model “without 5015 Fan” in combination with this model to use the Stock 4010 Dual fans. I did not try this, but should work. (you need to trim off the little stand offs on the back side with a modifier in Prusa Slicer)
    

Printing

i printed all parts out of PETG with 0.2mm Layer height and 3 Perimeters, 3 top and 3 Bottom Layers, 10%Gyroid Infill. 
The Perimeters give it more rigitity, infill won't do much on this design due to the thin walls.
If not obvious, print it flat on the side where the SO3-Fan will be and support the small hanging walls.

Installation and Printing Tips

1. Fitting tolerances are very dependent on you printer - please print different tolerances
   try the 3 different fitted tension-inserts for the best fit - i have used the 0,2 (0,1 on all sides) which barely fits but it will not ever come loose again, so i reccomend the 0,3 or 0,4 ones.
2. you have to be careful not to have any cables in the homing area, so behind the Fan Duct and also outside of the trigger switch.
   Best to have the cables in the front, if you want to make sure it wont collide when homing when keeping all connectors (i had to remove the Molex Connector on the heatbreak)
3. installing the belt: 
   i mounted the fixed side first, then the belt tensioning side. 
   
   3.1 to install the fixed side pull it through the hole , fold it, so the teeth interlock, then pull it back. its tight, but it works. Don't forget to put a 5mm long Filament piece into the loop on the inside to hold it in place (see picutre 13 for result)
   
   3.2 to install the tensioning side also do a loop and secure it with filament.
   to check the length hold it just beside the casing, measure the distance, ajust the length.
   (see picutre 14 for result)
   
   Caution: don't over tighten your belts, its hard to un-tighten them.
   
   If you need more details, please comment. - i will try my best to answer.
    

Pictures

i hope the pictures can tell you more than words, but here i am, making comments on pictures

• pictures 5, 6 , 7: 
  cable management, its not perfect, but something.
• pictures 8 and 9: 
  If you use 5015 Fan: i bent the Y-axis switch to trigger sooner
• pictures 10, 11, 12:
  assembly explosion to get an idea what goes where.
• picture 13:
  fixed belt side 
• picture 14:
  you dont have to cut the belt, i let it stick out a bit
• picture 15:
  the belt tension mechanism before installment. - you have about 10mm of belt tensioning 

inspirations that should not go unmetioned

• SO3 Fan mount 
• e3d v6 mount and belt tensioner

CAD Files to modify

Included files:

• iges assemby
• F360 file of Mount (with belt tensioning) to modidy
• F360 file of the Fan Duct.